Hello All, I have been researching different materials to substitute the cork used on the brake fluid reservoir switch assembly. I have heard of failing cork and different methods to coat the cork. My bench testing has concluded the following.
I am using a 1 inch diameter hollow polypropylene ball, purchased from McMaster Carr (Part #9338K11). Here is my process:
A. Remove aluminum cup surrounding the cork float, then remove old cork from sensor metal rod (rod is .080 inch diameter)
B. Swage with small hammer or file crimped end of sensor metal rod so as the easily remove brass washer. Be sure the crimped end is now a bit smaller in diameter than the .080 inch metal rod
C. Drill.073 inch (#49 drill bit) hole (centered) through the hollow polypropylene ball (I used a tool room lathe so the hole is centered)
D. Press on the hollow polypropylene ball on the sensor metal rod. Be sure it is a tight fit.
E. Place brass washer on the sensor metal rod and re-crimp the end using a small hammer. Check to be sure washer cannot come off.
F. Replace aluminum cup and crimp as needed

The rebuilt brake reservoir should be ready for service.

 

Hello All,
An update modification to the hole size in the polypropylene ball. Use #50 drill, (.070 inch diameter bit). The ball should be a very tight press fit onto the shaft.

Thanks.. Dave